Probing machine



Oct. 9, 1962 1... J. VANDEN BERG 3,057,007

PROBING MACHINE Filed Feb. 29, 1960 6 Sheets-Sheet l A I l k w 1 I A- I 1 f 3 v i INVEN TOR. jeazr' J l drrj'wja rf.

fi 3.42 I awuz/s.

Oc 1962 L. J. VANDEN BERG PROBING MACHINE 6 Sheets-Sheet 2 Filed Feb. 29, 1960 Oct. 9, 1962 1.. J. VANDEN BERG PROBING MACHINE 6 SheetQs-Sheet 3 Filed Feb. 29, 1960 1962 L. J. VANDEN BERG 3, 57,007

PROBING MACHINE Filed Feb. 29, 1960 6 Sheets-Sheet 4 6 Sheets-Sheet 5 IN VEN TOR. J." lwJeW Z02 L. J. VANDEN BERG PROBING MACHINE Oct. 9, 1962 Filed Feb. 29, 1960 186x 67 BY Oct. 9, 1962 L. J. VANDEN BERG PROBING MACHINE 6 Sheets-Sheet 6 Filed Feb. 29, 1960 r L. M

United States PatentO 3itl57,tltl7 PROBING MACHINE Lester J. Vanden Berg. Grand Rapids, Mich, assignor, by mesne assignments. to Evans Products Company, Plymouth Township. Mich, a corporation of Delaware Filed Feb. 29., 19%. Ser. No. 11,511 6 Claims. (Cl. 181) This invention pertains to a probing machine for simultaneously advancing a plurality of probe elements which are adjustably positionable through a directionally guided line of travel.

The principles of this invention are particularly applicable to a machine suitable for manufacturing nonplanar sandwich panels of a preselected contour which comprise a light weight foamed resinous core and more dense facing or cover sheets secured to the face. surfaces of the core. Sandwich panels of this general type are now well known and their light weight, structural rigidity, and excellent thermal and sound insulating properties make them ideally suitable for assembly into complete articles such as boats, swimming pools, vehicle bodies, refrigeration enclosures, building structures of various types, etc.

Generally, sandwich panels of a planar configuration can be commercially fabricated from separately preformed cores and cover sheets which are assembled and adhesively secured together into a unitary panel. Nonplanar panels, however, particularly panels having compound curvatures are difficult to manufacture from preformed cores and preformed cover sheets of the desired contour and with sufficient accuracy to assure easy assembly with mating contoured surfaces. Moreover, cutting an appropriate preformed core from a larger piece is wasteful of both labor and raw material, and therefore constitutes an inefiicient and expensive mode of manufacture. In addition, the successive manufacture of nonplanar panels having identical contoured surfaces requires exacting manufacturing and assembly techniques further detracting from the eiliciency and economical production of nonplanar panels. One specific embodiment of the present invention overcomes the foregoing problems by providing a machine for simultaneously and uniformly expanding a thermoplastic resinous material between appropriately contoured cover sheets forming therewith a unitary panel.

In accordance with this manufacturing method for forming nonplanar panels, one or mOre dense planar cover sheets are positioned in a mold having a preselected contour with the outer surface of the cover sheet being positioned in contact with the adjacent mold surfaces and filling the cavity between the cover sheets with a partially expanded synthetic resinous material in a bead or pellet form. Appropriately positioned probes are then inserted into the resinous material between the cover sheets and a hot fluid such as air, superheated steam, or combinations thereof, is injected into the cavity from the probes whereby the resinous beads are expanded and united together and to the interior surfaces of the cover sheets thereby forming a unitary composite panel that permanently retains the curvature of the mold surfaces. Thermoplastic resinous materials suitable for forming a foamed core between two cover sheets include polystyrene, polyvinyl chloride, polyvinylidene, polyvinylidene chloride, polyacrylic esters, polymethacrylic esters, polyacrylonitrile, styrene-butadiene interpolymers, etc., and of this group polystryene represents a preferred material. The synthetic resinous materials in a head or pellet form are pre-expanded to an approximate density ranging from about one-half pound to about ten pounds per cubic foot in a drum-type pre-expander having suitable agitation means therein and a heating source such as steam which is controllable in quantity and heat content to expand the beads to the desired density. To effect a foaming of the synthetic resinous materials an organic raising agent is employed which may be a low boiling point hydrocarbon, boiling in the range of about F. to about P. such as pentane, hexane, heptane, petroleum ether, cyclopentane, cyclohexane, etc., and which raising agents represent between about five percent to about twenty percent by weight of the resinous beads. Final expansion and fushion of the resinous beads in the cavity of the mold is achieved by inserting the probes of the probing machine and injecting a heated fluid whereby the temperature within the cavity is elevated to a range of about 275 F. to about 285 F.

As the size and complexity of curvature of the panels increase it becomes increasingly difiicult to manufacture cores having uniform pore size of the expanded resinous core and which is free from fisures or areas of poor adhesion to the cover sheets. The probing machine of this invention overcomes these difficulties by directionally guiding each of the plurality of probes between the curved cover sheets and withdrawing them at a controlled rate whereby a uniformly expanded core securely bonded to the cover sheets is obtained.

Another objective of this invention is to provide a probing machine that is simply and quickly adjustable so that the angularity of the line of travel of each of the probing elements can be adjusted to any preselected position. Extreme flexibility of the probing machine is thereby achieved, whereby nonplanar panels of a variety of different sizes and curvatures are adaptable for manufacture by this machine. Once the machine is adjusted for a particular curvature as defined by the angularity of the path of travel of each of the probes, a series of curved sandwich panels can be manufactured in rapid succession which have identically contoured surfaces.

Still another object of this invention is to provide a probing machine that is of durable construction, simple in operation and substantially free of malfunctioning components.

Other objects and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the following drawings, wherein:

FIGURE 1 is a perspective view of a probing machine constructed in accordance with the preferred embodiments of this invention;

FIG. 2 is a fragmentary rear elevation view of the probing machine shown in FIG. 1;

FIG. 3 is a side elevation view of the probing machine shown in FIG. 2 and positioned in relation to a mold of, for example, the compound curvature type disposed adjacent to and longitudinally of the machine;

FIG. 4 is a vertical longitudinal sectional View through the carriage trackway of the base frame shown in FIG. 3 and taken along line 4-4 thereof;

FIG. 5 is a horizontal sectional view through an upright carriage column shown in FIG. 3 and taken along line 5-5 thereof;

FIG. 6 is a transverse sectional view through a manifold slideway shown in FIG. 3 and taken along line 6--6 thereof;

FIG. 7 is a fragmentary elevational view of the forward probe guide plate and mounting bracket slidably positionable on the manifold slideway;

FIG. 8 is a side elevational view of a short probe and movable front guide assembly slidably mounted on a manifold slideway;

FIG. 9 is a transverse sectional view through the manifold slideway showing in particular the movable front guide assembly shown in FIG. 8 and taken along line 99 thereof;

FIG. 10 is an enlarged fragmentary perspective view of a probe and showing in particular the apertures disposed in the forward end portion thereof; and

FIG. 11 is a perspective view of a typical curved mold adaptable for the manufacture of nonplanar sandwich anels.

p Referring now to the drawings, and as may best be seen in FIGS. l-3, a probing machine incorporating the preferred embodiments of this invention is comprised of a base frame 20 on which a super structure is stationarily and movably mounted for supporting and guiding a plurality of probes through a preselected path of travel. Base frame 20 is comprised of a series of front legs 22 and rear legs 24 of a channel cross-section which are rigidly secured at their lower ends to the floor or other suitable foundation by means of anchor brackets 26. Transverse channels 28 are rigidly supported on front legs 22 and rear legs 24, the upper surfaces of which are provided with a T shaped trackway or rail 30 rigidly secured thereto. A pair of longitudinal channels 3-2 are disposed horizontally between the inner surfaces of rear legs 24 and rigidly secured thereto. A suitable drive mechanism is mounted on lower longitudinal channel 32 such as electric motor 34 and variable speed reducer 36 drivingly connected together by flexible belt 38. Electric motor 3 4- is mounted on an adjustable motor base 41) which is rigidly secured to the upper surface of longitudinal channel 32. The output torque of motor 34 is transmitted to speed reducer 36 by flexible belt 38 extending around motor pulley 41 and speed reducer pulley 42 and which, through suitable reduction gearing is transmitted to trans verse output shaft 4-4 having a drive sprocket 46 fixedly mounted thereon. Shaft 48 is disposed between and journaled through the upper end portions of rear legs 24 to which driven sprocket 50 is fixedly secured and in vertical alignment with drive sprocket 46. Sprocket chain 52 extends around drive sprocket 46 and driven sprocket 50 and is encased at its upper end by chain cover 54. Splined on the outer ends of shaft 48 are sprockets 56 each of which are in engagement with chains 58 extending around a similar pair of idler sprockets 6i! rotatably mounted on fixed shafts 62 secured to the forward end portions of transverse channel 28 and in transverse alignment with sprockets 56. The ends of chains 58 are secured to carriage 64 which is longitudinally disposed on the base frame 20 and movably mounted on T-track 30 as may be best seen in FIG. 4. As shown therein, carriage 64 is comprised of an inverted U-shaped member 66 having a pair of transverse rollers 68 extending inwardly from each of the depending side flanges thereof and adapted to alternately contact the upper surface of transverse channel 28 and inner surface of Trail 30. Side rollers 70 are horizontally disposed and rotatably mounted in each of the depending flanges of U-shaped bracket 66 and are adapted to contact the side edges of rail 30 maintaining carriage 64 in appropriate alignment therewith. A horizontal I-beam 72 is rigidly secured to the upper surface of each of U-shaped brackets 66 and provides the supporting base for the movable super structure above.

The carriage driving mechanism is provided with a suitable start-stop-reverse push button switch 74 whereby carriage 64 is caused to move laterally between a forward position and a rear position along T-rail 30. The lateral movement of carriage 64 between the forward and rear positions may be controlled by a pair of suitable limit switches (not shown) longitudinally positionable along T-rail 30 and actuable in response to the movement of the carriage 64 therealong. Actuation of the forward or rear limit switch would automatically de-energize electric drive motor 34 thereby halting the lateral movement of carriage 6.4 in the appropriate forward or rearward position, respectively. Energization of motor 34 is achieved by manually depressing a push button of switch 74 which overrides either limit switch and maintaining the push button depressed until carriage 64 has moved sufliciently to release the limit switch.

A series of upright columns 76 are fixedly secured at spaced intervals to the web portion of longitudinal I-beam 72 by welding, bolting or the like. Upright columns 76 are reinforced by a longitudinal channel stringer 78 extending along the upper portions of the columns and rigidly secured to the rearward surfaces thereof. The forward vertical edge of upright column 76 is provided with a T-shaped rail 86* extending substantially the entire length thereof and along which roller bracket 82 is movably mounted. As may be best seen in FIG. 5, roller carriage 8'2 is comprised of a base plate 84 and rectangular depending leg portions 86 disposed in parallel spaced relation and rigidly secured to the side edge surfaces of base plate 84 by securing means such as screws 88. The inner portions of legs 86 are provided with a pair of side rollers 90 which are adapted to roll along the side portion of T-shaped rail 80 maintaining roller bracket 82 in transverse alignment therewith. In addition, a pair of transverse rollers 92 extending inwardly from each leg 86 are adapted to alternately bear against the forward vertical surface of upright column 76 and the inner parallel surface of T-rail 8% interlocking roller bracket 82 with T-rail 8t and limiting its lateral movement with respect thereto. Manifold pipe section 94 is securely clamped to the forward surface of base plate 84 by means of transverse strap 96 overlying the forward surface of manifold section 94 and secured to base plate 84 by bolts 98 in threaded engagement therewith. By this arrangement the lateral movement of carriage 64 is transmitted to manifold section 94 movably mounted on vertical column 76.

As shown in FIGS. 1 to 3, the composite header or manifold 3 is comprised of a series of manifold sections 94 sealed at their ends and disposed in spaced substantial end to end alignment with adjacent sections and extending longitudinally along the machine. The mid-point of each manifold section 94 is secured to roller bracket 82 as heretofore described, which is vertically movable along the forward surfaces of upright columns 76. Each of the end portions of manifold sections 94 are movably supported on slide brackets 1% movably mounted on slide- Ways 1&2 disposed in parallel spaced relation and extending between the forward and rearward portions of the base frame 21). The forward and rearward ends of slideways 102 are connected to and adjustably positionable on vertical front and rear supports 1114 and 106 respectively. The lower portions of vertical front supports 104 are rigidly aflixed to longitudinal *I-beam 108 which is rigidly supported along the front portion of the base frame, such as by U-bolts 109 afiixed to posts 111 comprising a portion of press 112 disposed along the front of the probing machine. The rear supports 106 are fixedly mounted in a vertical position having the lower ends thereof rigidly secured to longitudinal channel brace 114 extending along the rear portion of the base frame and secured to rear legs 24 and transverse channels 28. Front supports 104 and rear supports 106 are comprised of angle iron structural elements and are disposed in pairs with the projecting flanges thereof in opposing spaced relationship and to which are secured T-shaped slide tracks 116. Slidably mounted on each slide track 116 is a U-shaped slide shoe 118 which is adjustably positionable therealong and locked with respect thereto by locking screws 120.

Slideways 102 are of a similar construction to front and rear supports 104 and 106, respectively, comprising an angle iron stringer having elongated slots 122 disposed along each end portion of the vertical flange thereof and a T-rail 124 fixedly secured to the horizontal flange surface on which slide brackets are movably mounted. Slideways 102 are adjustably aflixed to slide shoes 118 by stud 126 secured to shoe 118 that extends through slot 122 of slideway 102 and is provided with securing nut 128 in threaded engagement therewith as may be best seen in FIG. 2. The adjus-tability of slide shoes 118 along vertical front and rear supports 104 and 106, respectively, coupled with the slidable connection provided by slots 122 in slide rail 102 enables each slide rail to be independently and angularly positionable in a vertical transverse plane. Accordingly, by adjusting the angularity of each pair of slideways 102 the appropriate longitudinal inclination of manifold sections 94 can be obtained. To permit substantial angular deflections of manifold sections 94 the ends thereof are pivotally mounted on slide brackets 100, as may be best seen in H6. 6. Slide bracket 180 is similar in construction to roller bracket 82 comprising a base plate 84 having depending leg portions 86 secured thereto. The side legs 86 incorporate pairs of side rollers 90 and transverse rollers 92 to minimize friction and guide slide bracket 100 along T-rail 124. The upper surface of base plate 84 is provided with pivot block 130 secured thereto by recessed screws 132. Pivot block 130 is of a triangular configuration having the apex thereof disposed substantially at right angles to the longitudinal center line of manifold section 94 and in tangential contact with the periphery there-of. An aperture or groove 134 extends longitudinally through the base of a pivot block 130 in which the bight portion of U- clamp 136 is pivotally mounted. The leg portions of U-clamp 136 extend upwardly through transverse strap 138 and have nuts 140 in threaded engagement with the ends thereof clamping manifold section 94 against pivot block 130. The upper edge portions of base plate 84 may be chamfered as at 144 to enable unrestricted pivotal movement of manifold section 94.

A plurality of fittings such as pipe couplings 146 are rigidly secured at spaced intervals along the forward edge of manifold section 94 having the interiors there-of communicating with the interior of the manifold section. A tubular probe 148 is connected to each coupling 146 and is slidably supported along its forward end by aperture 150 in probe guide plate 152. Each probe may be provided with a suitable variable fiow valve 154 (FIG. 8) whereby the discharge of the heated fluid from manifold section 94 through the probe can be regulated to any desired volume.

Probe guide plate 152, as may be best seen in FIG. 7, is adjustably mounted to upstanding bracket 156 by a screw and wing nut assembly 158. Transverse slot 160' in probe guide plate 152 and vertical slot 162 in upstanding bracket 156 enables guide plate 152 to be vertically and angularly positionable with respect to slideways 102. Up standing bracket 156 is rigidly secured to slide clamp 164 adjustably slidable along T-rail 124 and locked thereto by lock screw 166. By this arrangement probe guide plate sections 152 corresponding in length to manifold sections 94 may be positioned along slideways 102 and angula-rly inclined therebetween so as to provide continuous guided support of probes 148 during their forward and rearward travel.

In the specific embodiments of this invention herein described probes 148 are adapted to be inserted within the cavity of a compound curvature mold ejecting a heated fluid from the end portions thereof whereby resinous pre-expanded beads contained within the cavity are united into a unitary core. The heated fluid is supplied to each of the manifold sections 94 from a main supply line 168 which extends longitudinally above the machine and is secured to the upper ends of rear supports 106 by clamping means such as U-bolts 170. Main supply line 168 is connected to each manifold section 94 by suitable flexible pipe means or hoses 172 of a length sufficient to permit unrestricted forward travel of the manifold sections. Although compressed heated air provides a satisfactory means for expanding the prefoamed resinous beads the preferred practice utilizes a superheated steam supplied at a line pressure of between about thirty to about one hundred pounds per square inch, which is 6 introduced into the cavity from apertures or jets disposed in the forward end of the probes 148.

The lengths of probes 148 extending transversely from manifold sections 94 vary in length to accommodate variations in the depth or breadth of the mold cavity. All the probes are simultaneously advanced toward the mold during the forward lateral movement of the composite manifold from its rearward position. In the manufacture of nonplanar panels which deviate substantially in depth, it may be necessary to employ probes along sections of the machine that are shorter in length than the lateral stroke or travel of composite manifold and carriage 64. Under these circumstances, the short probes would be withdrawn from apertures in guide plates 152 adjustably mounted on the forward portions of slideways 1532 leaving the probes unsupported and unguided for the next forward stroke. Moving slide clamps 164 rearward along slideways 102 to compensate for the short length of the probes would cause interference between slide brackets 100 and slide clamps 164 during the forward movement of the composite manifold. Accordingly, it is necessary to provide movable front probe guides along those portions of the probing machine wherein short guides are disposed which provide continuous guidance of the probes and yet will not interfere with the forward travel of slide bracket 100 along slideway 102. A satisfactory movable probe guide assembly is illustrated in FIGS. 8 and 9. Probe guide plate 152 is adjustably mounted on upstanding bracket 174 secured to the upper surface of guide roller bracket 176, which is movably mounted on T-rail 124. Guide roller bracket 176 is comprised of a base plate 178 to which side leg portions 180 disposed in spaced parallel relation are securely attached by means of screws 182. A pair of side rollers 184 are rotatably mounted on .each side leg 180 and are adapted to contact the side portions of T-rail 124. Transverse rollers 186 extend inwardly and are disposed between the upper surface of the angle iron stringer of slideway 102 and the inner surface of T-rail 124 thereby laterally and longitudinally aligning guide roller bracket 176 along slideways 102. A tie rod 188 extends between slide bracket 100 and guide roller bracket 176 and is adjustably connected at its forward end by lock nuts 189 to the depending flange of angle bracket 190 secured to the lower portion of one of the legs 180 of guide roller bracket 176. The other end of the tie rod 188 extends through aperture 191 in depending flange of angle bracket 192 secured to the lower portion of slide bracket 100. Coil spring 193 extends around the end of tie rod 188 having the forward portion thereof in abutting relation with the rearward surface of the depending flange of angle bracket 192 and the rearward portion thereof in abutting relationship with washer 194 held in position by lock nuts 196 in threaded engagement with the ends of tie rod 188. Guide roller bracket 176 is biased toward the forward end of slideway 102 by a flexible element such as link chain 198 connected to guide roller bracket 176 and extending over sheave 200 rotatably mounted on angle bracket 202 secured to the forward end of slideway 102. The lower end of chain 198 (not shown) is weighted whereby a constant force is applied to guide roller bracket 1'76 biasing it toward the front portion of slideway 102. In operation, as carriage 64 moves forward manifold section 94 and slide bracket 100 also moves forward along slideway 102 and guide roller bracket 176 simultaneously moves along slideway 102 in constant spaced relation to slide bracket 100 with probes 148 supported in guide plate 152. When the forward end of guide roller bracket 176 contacts angle bracket 202 disposed at the forward end of T-rail 124 its forward motion ceases and slide bracket 100 continues to move forward whereby the rod 188 slides through the aperture 181 in angle bracket 192 and probes 148 slide forward through apertures 150 in guide plate 152.

After a pre-' determined period in the forward position, the composite.

manifold 93 is retracted whereby probes 148 and slide roller brackets 100 move toward the rearward position and during which movement the depending flange of angle bracket 192 comes into abutting relationship with coil spring 193 which cushions the engagement of guide roller bracket 176 and gradually accelerates it from a standing position at the forward end of T-rail 124. Guide roller bracket 176 is pulled rearward by tie rod 188 in opposition to the biasing force applied thereto by weighted chain 198 until the probing machine again returns to its rearward position. It will of course be appreciated that the length of tie rod 188 can be varied in accordance with the length of the probe 148 depending on the breadth of the specific panel being formed.

A typical mold for manufacturing nonplanar sandwich panels in conjunction with the probing machine herein described, may be best seen in FIGS. 3 and 11. As shown therein, mold 294 is comprised of a lower female portion 206 and an upper male portion 208 in overlying indexed relationship therewith. Female mold section 2% is provided with a contoured surface 210 which defines the curvature of one surface of the nonplanar panel and an internal end surface 212 defining the end and breadth of the nonplanar panel. Male mold portion 208 is provided with contoured surface 213 correspondingly contoured and spaced from surface 210 of the female mold portion, which together with end surface 212 de fines a cavity having a configuration corresponding to the finished sandwich panel. The exterior edge surface of the mold cavity is defined by a front closure plate 214 overlying the side surfaces of the male and female mold portions and is secured along its lower edge to the female mold portion 206 by a plurality of bolts 216 spaced therealong. The upper edge portion of plate 214 is provided with a plurality of receiving apertures 218 disposed at spaced intervals and corresponding to the spacing of locating pins 220 aflixed to the side of male mold portion 208. The coaction between locating pins 220 and receiving apertures 218 serves to align and support the upper mold portion in its lowered position over lower female mold portion 206. Suitable gasketing material may be disposed on engaging surfaces between upper and lower mold portions and on the rearward face of closure plate 214 to effect a pressure tight seal of the mold cavity. Front closure plate 214 is provided with a plurality of apertures 222 disposed at spaced intervals therealong and coinciding with the spacing of probes 148 of the probing machine which are in adjustable alignment therewith.

Preparatory to the formation of a panel, the mold is assembled by first placing the lower female mold portion 206 on a suitable base such as cart 224 movably mounted on a trackway 226 extending adjacent to and longitudinally of the front side of the probing machine. The lower mold surface 210 is then covered with a suitable facing sheet 227 the upper surface of which has been coated with a suitable adhesive. A plurality of prefoamed spacer blocks preferably of the same composition as the resinous beads to be employed, and having the approximate desired core thickness are positioned on the adhesive of the cover sheet and spaced over the surface. A second cover sheet 227a having the inner surface thereof coated with a similar adhesive is placed over the spacer blocks with the adhesive layer in contact therewith and the upper mold portion 208 is lowered into position and in engagement with lower mold portion 206. During the lowering of upper mold portion 208 the cover sheets 227, 227a deflect and assume the curvature of the upper and lower mold surfaces 210 and 213, respectively, and are maintained in that curvature by the spacer blocks disposed therebetween. Alternatively, the cover sheets 227, 227a may be detachably secured by suitable securing means to the upper and lower mold surfaces 210 and 213, respectively, prior to the lowering of the upper mold whereby the cover sheets are held in the appropriately contoured positions. The mold is clamped together and the cavity is then filled with a quantity of pre-expanded resinous beads as heretofore described by injecting the same through, for example, apertures 222, preferably through a nozzle using air as the propelling means. The clamped and assembled mold is then moved into position longitudinally of the forward end of the probing machine and the lower platen 224 of press 112 is raised maintaining contacting upper and lower mold surfaces in firm abutting relationship.

With the assembled mold 204 in appropriate alignment along the front side of the probing machine, the forward probe guide plate 152 for each header section and each corresponding pair of slideways 102 are adjusted so that each of the probes 148 are in axial alignment with the corresponding probe aperture 222 in the front closure plate 214. In addition, the transverse angularity of slideways 1'92 and longitudinal inclination of manifold sections 94 are adjusted so that the line of travel of the probe passes through substantially the midpoint of the resin filled cavity of the mold without interfering with either of tie exterior cover sheets. Drive motor 34 is then energized causing carriage 64 to move forward whereby the probes are simultaneously inserted into the resin filled mold cavity until the forward ends thereof are adjacent to the interior end surface 212. Main control valve 230 disposed in the main supply line 163 which may be solenoid actuated is then opened permitting a pressurized heated fluid to be discharged from the ends of probes 148 into the mold cavity.

Injection of the heated fluid into the mold cavity may be achieved by a plurality of apertures or jets peripherally disposed around the forward portion of the probe 148, and offset from the apertures in adjacent probes so as to provide optimum distribution of the heated fluid throughout the adjacent space. In lieu of a plurality of peripheral positioned apertures along the forward length of the probe, the preferred probe construction utilizes a series of jets 232 spaced around the tapered forward end surface of the probe as shown in FIG. 10. The jets 232 as shown, are triangular in shape and the sides thereof taper inwardly from the base of the triangle to the apex which is located at or immediately adjacent to the end extremity of the probe, and disposed in the tapered end surface portion thereof. Four jets 232 disposed apart have been satisfactorily employed although a smaller or larger number could be used. In a typical commercial probe, the width of the base portion of triangular jet 232 may be about 2 to about of an inch, and the height of the triangular jet may be about to about 4 inches. The tapered end portion of each probe 148 provides a peripheral cam surface facilitating alignment of the probe with probe apertures 222 during the insertion of the probes and reduces the force required to advance them through the resin filled mold cavity.

After the discharge of the heated fluid for a predetermined time interval while the probing machine is in the fully forward position electric drive motor 34 is energized slowly withdrawing the probes at a uniform rate to effect a fusion and consolidation of the resinous beads and adhering them to the surfaces of the exterior cover sheets. In the preferred practice, a superheated steam is employed to heat the resinous beads within the mold cavity and minimize the entrapment of moisture therein. It will be apparent of course, that probes 148 occupy a space within the expanding resinous bead which would represent voids or discontinuities in the final core unless the beads are expanded to fill this space as the probes are withdrawn from the cavity. Accordingly, by maintaining a constant discharge of steam from jets 232 and withdrawing the probes at a rate sufliciently slow to cause the beads to expand and fill the space formerly occupied by the probe, a homogeneous core can be obtained devoid of any discontinuities therein. Moreover, the discharge of steam is preferably continued until 9 the ends of the probes are completely withdrawn from the cavity to ensure that the exterior end surface of the core is uniformly filled with expanded beads.

The amount of heat necessary to form a homogeneous expanded core is dependent on the specific resin utilized for forming the core. Preliminarily expanded resinous beads of a polystyrene type resin for example, are effectively interfused at a temperature ranging from about 275 F. to about 285 F. Moreover, the quantity of heat supplied per unit volume of resinous materials should be substantially equal throughout the entire length and breadth of the panel to achieve uniform pore size. Accordingly, panels varying in thickness and breadth throughout their length and consequently varying in the volume of resinous beads disposed between the exterior cover sheets can be satisfactorily expanded by controlling the time and/or the pressure of steam supplied to the probes at various stations along the panel. Installation of suitable pressure-flow control valves 234 (-FIG. 2) in each of the flexible pipe means 172 supplying the superheated steam to each of the manifold sections 94 of the composite manifold coupled with the variable fiow valves 154 connected to each individual probe 148 provides means whereby the duration and pressure of steam ejected from each probe can be regulated to the desired magnitude. By this arrangement, the control valves 234 conmeeting each of a selected number of manifold sections 94 disposed adjacent the thicker sections of the panel may be opened at a predetermined time interval prior to that of the other valves and at a higher pressure setting to provide the appropriate quantity of heat required to interfuse the greater volume of resinous beads. While it is difficult to state a definite relationship between the pressure of steam ejected from each probe, time delays between applying steam to selected manifold sections, and the rate at which the probes are withdrawn from the cavity in the manufacture of nonplanar panels of various curvatures and configurations, the application of the foregoing principles to a specific panel and conducting a few trial runs will establish optimum operating cnditions. It is desired, although not necessary for the satisfactory operation of the machine, to provide probe apertures 222 in the front mold closure plate 214 with a resilient gasket adapted to envelop the probe forming a slidable sealing surface that inhibits leakage of steam from the pressurized mold cavity while the probes are disposed in the mold cavity.

The extreme adjustability features of the probing machine herein described enables the manufacture of a variety of different nonpolar panels having complex curvatures and variations in the depth and thickness of the panel. For each specific panel the longitudinal inclination of each of the manifold sections 94 comprising the composite manifold 93 is adjusted to conform with the longitudinal curvature of the nonplanar panel to be manufactured. In addition, the transverse inclination of each of the probe elements is adjusted to the angle of inclination of the mold cavity as it changes from end to end in the panel. Each of the manifold sections 94 comprising the composite manifold need not necessarily be of the same length. Longer manifold sections 94 may be employed along sections of the nonplanar panel wherein the severity of the longitudinal curvature thereof is substantially small and conversely shorter manifold sections 94 are required to enable appropriate orientation of the probes along those sections where the severity of the longitudinal curvature of the panel is great. In lieu of substantially short manifold sections 94, it will be appreciated that curved sections may be employed corresponding in shape substantially to the longitudinal curvature of the panel. In addition, the flexibility provided by the valving control means enables panels of varying length to be fabricated by this machine.

While it will be apparent that the preferred embodiments herein illustrated are Well calculated to fulfill the objects above stated, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope or fair meaning of the subjoined claims.

What is claimed is:

1. A probing machine comprising a frame, a plurality of slideways disposed at longitudinally spaced intervals and independently adjustably mounted transversely of said frame, a plurality of manifold sections disposed in spaced substantially end to end relationship and extending longitudinally along said frame, each of the end port-ions of each of said manifold sections movably mounted on one of said slideways for guidably supporting said manifold sections and providing for independent adjustment of the longitudinal angularity thereof, a plurality of probes connected at spaced intervals to the forward portion of each of said manifold sections and extending transversely of said frame, guide means longitudinally disposed along the front portion of said frame for supporting and maintaining said probes in appropriate transverse orientation and moving means connected to each of said manifold sections operative to laterally move said sections along said slideways to and from a forward position and a rearward position.

2. A probing machine comprising a frame having a front portion and a rear portion, a plurality of slideways extending transversely at spaced intervals between said front and said rear portions of said frame and independently adjustably secured thereto, a plurality of manifold sections disposed in spaced substantially end to end relationship and extending longitudinally along said frame, each of the end portions of said manifold sections movably mounted on one of said slideways for guidably supporting said manifold sections and providing for independent adjustment of the longitudinal angularity thereof, a plurality of tubular probes connected at spaced intervals to the forward portion of each of said manifold sections and extending transversely of said frame toward the front portion thereof, the interiors of said probes communicating with the interiors of said manifold sections, a plurality of apertures in the forward end portion of each of said probes, guide means longitudinally mounted along the front portion of said frame for supporting and maintaining said probes in appropriate transverse orientation, pipe means connected to each of said manifold sections, and moving means associated with each of said manifold sections operative to laterally move said sections along said slideways to and from a forward position and a rearward position.

3. A probing machine comprising a base frame having a front portion and a rear portion, a carriage longitudinally disposed on said frame and laterally movable thereon to and from a rear position and a forward position, moving means associated with said carriage for laterally moving said carriage between said positions, a composite manifold comprising a plurality of manifold sections longitudinally disposed in spaced substantially end to end relationship along the length of said frame and movably mounted on said carriage and laterally movable thereby, a plurality of slideways transversely mounted on said frame and extending between said front and said rear portions thereof and independently angularly adjustable in a vertical plane, each of the end portions of each of said manifold sections slidably mounted on one of said slideways and movable therealong for guidably supporting said manifold sections and providing for independent adjustment of the longitudinal angularity thereof, a plurality of hollow probes disposed in spaced apart relation connected to the forward edge of each of said manifold sections and having the interiors thereof in communication with the interiors of said manifold sections, a plurality of discharge apertures in the forward end portion of each of said probes, probe guide means adjustably mounted along the front portion of said frame for slidably supporting said probes, flexible pipe naeans con- 11 ne'cted to each of said manifold sections for supplying a pressurized fluid thereto, and valve means in said flexible pipe means and said probes for selectively regulating the pressure of fluid supplied to said probes.

4. A probing machine comprising a frame having a front portion and a rear portion, a carriage extending longitudinally along said frame and laterally movable thereon to and from a forward position and a rear position, moving means connected to said carriage for later ally moving said carriage in a horizontal plane between said positions, a plurality of upright columns mounted at spaced intervals along said carriage, a plurality of slideways extending transversely at spaced intervals between said front and said rear portions of said frame and adjustably secured thereto, a plurality of manifold sections disposed in spaced substantially end to end relationship and extending longitudinally along said frame, each of said manifold sections movably mounted substantially at the midpoint thereof to one of said upright carriage columns and each end portion of each of said sections movably mounted on one of said slideways, said slideways guidably supporting said manifold sections and providing for independent adjustment of the elevation and longitudinal angularity thereof, a plurality of tubular probes connected at spaced intervals to the forward portion of each of said manifold sections and extending transversely of said frame toward the front portion thereof, the interiors of said probes communicating with the interiors of said manifold sections, a plurality of apertures disposed in the forward end portion of each of said probes, guide means adjustably mounted longitudinally along the forward portion of said frame for slidably supporting and maintaining said probes in appropriate transverse orientation, flexible pipe means connected to each of said manifold sections for supplying a pressurized fluid thereto, and valve means in said pipe means for selectively regulating the pressure of fluid supplied to said probes.

5. The probing machine as described in claim 3, wherein at least a portion of said probe guide means comprise a movable probe guide assembly extending transversely of and movably mounted on the forward portions of a pair of said slideways and movable therealong, linkage means connecting said movable probe guide assembly and said manifold section and restricting the maximum lateral spacing therebetween to a distance less than the length of said probes, urging means associated with said movable probe guide assembly biasing said assembly toward the forward end of said pair of slideways, and stop means associated with said slideways and operative to coact with said movable probe guide assembly to limit the forwardmost travel thereof.

6. The probing machine as described in claim 4 wherein at least a portion of said guide means for supporting said probes comprise a movable probe guide assembly comprising a pair of guide roller brackets movably mounted on the forward portions of a pair of said slide ways, a guide plate extending transversely between said pair of slideways and having each end portion thereof adjustably affixed to one of said guide roller brackets, a plurality of apertures longitudinally disposed at spaced intervals along said guide plate and adapted to slidably support said plurality of probes extending therethrough, linkage means connecting each of said guide roller brackets to said manifold section and restricting the maximum lateral spacing between said manifold section and said guide plate to a distance less than the length of said probes, urging means associated with each of said guide roller brackets biasing said brackets toward the forward ends of said slideways, and stop means associated with said slideways and operative to coact with said guide roller brackets to limit the forwardrnost travel thereof.

References (Iiterl in the file of this patent UNITED STATES PATENTS 1,840,027 Fetter Jan. 5, 1932 2,146,546 Lindemann Feb. 7, 1939 2,490,765 Abbott Dec. 13, 1949 2,760,222 Andersson Aug. 28, 1956 OTHER REFERENCES Koppers booklets, technical manual, Dylite Expandable Polystyrene: Equipment Requirements For Molding Dylite Expandable Polystyrene, Bulletin C9273, chapter 3a, Nov. 15, 1959, page 12. Mold Techniques and Mold Design, Bulletin C9273, chapter 3e, Nov. 15, 1959, pages 22 and 23.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. a osnoov Octobenu9 1962 Lester J. Vanden Berg It is hereby certified that error appears in the above numbered patent requiring correction and that the said Letters Patent should read as corrected below.

Column l line 66, for "'polystryene" read polystyrene column 2, line 4', for "85 F." read 85 F. column 6 llne 22' for 'the"; first occurrence read tie column 9 llne 28 for ,"the'fl, first occurrence read to line 5O for nonpolafl read nonplanar Signedand sealed this lthd'tay of July 1963a (SEAL) Attestz' DAVID L. LADD Commissioner of Patents ERNEST W. SWIDER Attesting Officer 

